IPO Unloading Valve Technology Developments and

The Associated Benefits

Alan Brodie, Feb 2011

IPO unloading valve technology developments Introduction

• IPO Unloading valve operation reminder• What the industry wanted in tomorrows unloading valves• What’s different about PTC unloading valves• The benefits these differences are delivering

IPO Unloading valve operation reminder

• Required during gas lift well commissioning– Where lift gas pressure can’t facilitate deep lift

• During unloading they should have: – Predictable operating characteristics

( opening and closing pressures)– High as possible throughput

• After unloading they should: – Stay reliably closed for the life of the well– Not be a weak link in the primary well barrier envelope– Not allow shallow lift gas entry or multi-pointing

• Unless .............well conditions change or are unpredictable: – And lift gas via the operating valve becomes unachievable– Then the unloading valve should be capable of:

• Reliably acting as an operating valve

Open

Open

Open

Open

Pressure

Depth

Closed

Closed

Closed

Open

Pressure

Depth

IPO Unloading valve operation reminder

• Ball and seat valve set in side pocket mandrel • Also incorporates a check valve ( not shown here):

– To provide tubing > casing integrity • Held closed by an N2 charged dome• Annulus (P1) and Tubing (P2) pressure trying to open it• P1 acts on large bellows area P2 acts on the valve port:

– When pressures are high enough valve opens – Injection pressure dominates

• ....but tubing pressure still has an impact P 1

Pressured Dome

A b

A p

P 1

P b

P 2

The industry wish list for tomorrows unloading valves

• Improved Integrity: – Well barrier performance in line with packers and plugs

• Improved Reliability: – Life of well longevity– Fail safe architecture • Reduced well commissioning costs • Higher throughput for faster unloading • Ability to pressure test tubing and annulus with live valves in the well

• Improved Performance:– High pressure rating to enable deeper installations – Reduced valve throttling and chattering – Flexibility to use as an operating valve if well conditions change• Without compromising integrity or reliability

What’s different about PTC unloading valvesWell Integrity

• Incorporates well barrier accredited check valve module:– Optimised flow paths and long valve travel– Minimal erosion– Patented orifice check dart linkage

• Chattering virtually eliminated:

What’s different about PTC unloading valvesWell Integrity

What’s different about PTC unloading valvesWell Integrity

• Incorporates well barrier accredited check valve module:– Optimised flow paths and long valve travel– Minimal erosion– Patented orifice check dart linkage

• Chattering virtually eliminated: – Spring location (around dart) & size

• Robust and requires 25 psi dp to open• Achieved V1( <20 cc /10 mins based on ISO 14310) , even:

– As part of an unloading valve – After flowing erosive fluid through the valve

• A well barrier is for life not just to pass a FAT

What’s different about PTC unloading valvesReliability

• In addition to well barrier accredited check valves.........• The PTC IPO valves use a revolutionary bellows design • All dome seals and inflation valves are metal / metal:

– Reduces likelihood of dome pressure leakage: • Bellows rated to 10000 psi

– Usually operating well within range • No dp across bellows

– Tested up to 35000 cycles without failure:• Very low load rate ( flexible even at 10000 psi )

– Long stem travel / large valve opening– Little throttling / erosion / chattering

• Valve held closed by spring – Not by bellows pressure as is more common – Active fail safe closure mechanism in the event of

• dome pressure leak • bellows failure

– No multi-pointing

P 1

Pressured Dome

A b

A p

P 1

P b

P 2

What’s different about PTC unloading valvesReduced well commissioning costs

• Faster unloading rates– Long stem travel in both unloading and check valve modules:– Designed using computational fluid dynamics

• Faster completion pressure testing – Shearable unloading valves– Avoids the need to run dummy valves for tubing and annulus testing – Patented shear mechanism external to valve

• Works even with multiple valves in the well

What’s different about PTC unloading valvesImproved performance

• Bellows area larger than in most unloading valves:– Low R factor ......less tubing pressure sensitive

• More predictable performance• Bellows load rate ( stiffness) lower than in most unloading valves:

– Even at 10000 psi ......– Valve fully opens quickly with long stem travel

• Less throttling / chattering: – Ideal where conditions are uncertain or may change

• Unloader module becomes “practically invisible”• Unloader can be used as a shallow operating valve

– Without compromising well integrity or reliability • 10 k psi pressure rating:

– Valves can be used in deep or high pressure applications • Deeper lift depth results in higher production

P 1

Pressured Dome

A b

A p

P 1

P b

P 2

Conclusions

• A new generation of IPO valves are now available: – Their design is revolutionary and in many ways unique

• They are now delivering a step change in: – Well integrity

• Unique well barrier capability even after erosion testing – Reliability

• Unique high pressure low load rate bellows– Commissioning costs reduction

• Unique shearable unloaders– Performance

• Unique flexibility to use as an operating valve

Feb. 1 - 5, 2010 2010 Gas-Lift Workshop 13

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Feb. 1 - 5, 2010 2010 Gas-Lift Workshop 14

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